Leak Testing for Electric Vehicle Battery Packs
A high quality, repeatable leak test is crucial for high volume EV battery production. Even a small leak under the electrical headers or cooling ports could allow contamination or condensation into the battery pack itself, resulting in catastrophic damage to the most expensive component on any EV.
The electrical header connections mounted on EV batteries are generally brightly colored, glass filled polymers. Electrical header port sealing requirements have presented a significant challenge for EV engineers trying to achieve a leak tight seal with consistent compression around the port perimeter, particularly where small radius corners are present. While traditional o-ring seals are designed to effectively seal circular openings, EV battery pack electric header connections are often square, rectangular, or oval.
To overcome this challenge, FasTest partnered with EV industry leaders to create a superior sealing, longer-lasting solution. Our new BEV family of leak test connectors incorporate a proprietary actuation and seal design that provides a consistent seal around the entire perimeter of non-circular ports, in addition to the durability, accuracy, and consistency demanded by engineers working on high volume EV production.
Identify & Eliminate Leaks
Allow condensation/water into the cell, and Leaks and electrolytes Out of the Cell. Ensure all connections ports on battery are sealed and leak-tight to avoid the risk of contamination to battery cell. FasTest offers leak test Connection Tools for all electrical connection fittings.
Designs for Automation
Automation friendly and customizable to any electrical header connection. Tailored Connections Tools to fit your battery.
Improve Quality & Reduce Warranty Claims
Warranty claims are inherently expensive, especially when they involve an engine or battery. Precision engineered tools provide the highest quality connection and seal for accurate testing.
Full Package of Battery Pack Leak Test Connection Tools
BEVP
Automated to BEV Electrial Headers
BEVM
Manual Connections to BEV Electrical Headers
VDAM
Manual Connections to VDA Ports
VDAP
Automated Connections to VDA Ports
Why FasTest for Battery Pack Connection Tools
Accurate Connection & Sealing
Precision engineered tools provide the highest quality connection and seal for accurate testing.
Reduce Repetitive Motion Injuries
Easy-to-use one hand operation, eliminate the painful twisting motions of standard fittings.
Safely Connect in Seconds
Safety First
Durable Connection Tools
Engineered for precision and durability to withstand rigorous testing environments.
Quality Tools, Quality Tests
Engineered for the highest quality connection and seal. Reduce False Failures caused at the connection points.
Trusted by Leaders
FasTest can outfit your entire battery with BEV electrical header leak test connectors.
Connection Tools Designed for YOUR EV Battery.
Our new BEV family of leak test connectors incorporate a proprietary actuation and seal design that provides a consistent seal around the entire perimeter of non-circular ports.
Custom Engineered Solutions
We transform connection tools into tailor-made solutions to fit your exact requirements. Our Team of engineers will work with you to identify and design the optimal Connection Tool for your testing needs. Having difficulty sealing a unique port? Issues with clearance? Work with our dedicated team of Custom Experts to build your perfect solution.
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Connect with an EV Specialist
Battery Pack Leak Testing Resources